Synthesizing Hydrocarbons of Coal with Ethanol

ABSTRACT

A novel fuel for the gasoline-powered internal combustion engine and an additive for the diesel combustion engine is provided by producing an Ethanol/Coal synthesization that approaches the BTU content of Gasohol. In one implementation the synthesizing process is performed by extracting hydrocarbons from the coal using a release agent and synthesizing the extracted coal hydrocarbons with an ethyl alcohol product to produce a fuel suitable for use in an internal combustion engine.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present PCT patent application claims priority benefit of the U.S. provisional application for patent NO. 60/699,774 filed on Jul. 15, 2005 under 35 U.S.C. 1 19(e). The contents of this related provisional application are incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates generally to methods for producing a fuel. More particularly, the invention relates to methods of releasing hydrocarbons of coal in the presence of ethanol to produce a fuel.

BACKGROUND OF THE INVENTION

It has been known for more than a century that the gasoline-powered internal combustion engine can be fueled by ethanol, but it is not advised to operate a non-modified gasoline-powered internal combustion engine with pure ethanol. Ethanol does not evaporate as readily as gasoline. Hence, in automobiles that predate 1979 (pre-electronic fuel systems), the carburetor had to be modified. The carburetor jets had to be bored out and enlarged. The carburetor using ethanol ideally receives a nickel-based treatment to prevent corrosion.

An automobile that is powered by pure ethanol ideally has a fuel tank made of fiberglass or a metal tank that is coated with pure tin. The fuel lines are preferably cadmium brass. The fuel filter system is ideally re-dimensioned to allow a greater fuel outlet since ethanol is a thicker fluid than gasoline and will not flow readily through a gasoline-sized carburetor jet(s).

The octane rate is a number that represents the antiknock properties determined by the percentage of isooctane. The higher the number, the greater the antiknock properties. Most gasoline-powered automobiles have an 8 to 1-9 to 1 compression rate. Ethanol, which has a much higher octane content than gasoline, can take a compression-rate of 12 to 1-15 to 1. Accordingly, it would be desirable to have modified cylinders when using ethanol as a fuel.

The valve housing of most (if not all) gasoline-powered automobiles is made of cast iron. This valve-housing should be changed to an iron-cobalt synthetic alloy for use with an ethanol fuel and the valves should be of stainless steel or a stellite composition.

Gasoline-powered vehicles would benefit from a fuel tank of fiberglass or a metal tank coated with tin, a nickel-based treated carburetor, a valve housing of iron-cobalt and chromed valves.

It has been known since the Second World War, when petroleum was scarce in many European countries (e.g., France, Germany, Czechoslovakia, Hungary), that a gasoline-powered engine can be fueled by the fumes of coal and wood. A container with coal and/or wood at the rear of the vehicle would be ignited. The fumes would then be funneled into the carburetor.

During the late nineteen-thirties and early nineteen-forties, German and Swedish chemists learned how to extract the hydrocarbons from coal. Since then, the process has been little improved upon. A vacuum/steam process was involved that had been and remains expensive.

The following statistics illustrate the comparative features of ethanol, methanol, and gasoline fuels:

Energy Content Methanol 19.95 Ethanol 26.68 Gasoline 42-44

Heat Evaporation Methanol 1.150 Ethanol .913 Gasoline .297

Oxygen Content Methanol 49.9 Ethanol 34.7 Gasoline -0- (Note: Oxygen in fuel is known to hinder energy output)

British Thermal Units Per Gallon Methanol 62,800 Ethanol 84,400 Gasoline 125,000 Gasohol 120,900 (which is 90 percent gasoline and 10 percent ethanol)

A British Thermal Unit (BTU) is the amount of energy required to raise the temperature of one pound of water one degree Fahrenheit.

From, the above statistics it is evident that both ethanol and methanol are deficient in every category—Energy Content, Heat Evaporation, Oxygen Content and British Thermal Units—when compared with gasoline. Ethanol is superior only in octane rating.

Currently, a flexible fuel internal combustion engine that can be fueled by both gasoline and Ethanol has a limited availability in North America.

In view of the foregoing, there is a need for improved techniques for synthesizing hydrocarbons of coal.

SUMMARY OF THE INVENTION

To achieve the forgoing and other objects and in accordance with the purpose of the invention, a variety of techniques are described for synthesizing hydrocarbons of coal with ethanol.

One aspect of the present invention is to provide methods for producing a novel fuel for the gasoline-powered internal combustion engine and an additive for the diesel combustion engine. Another aspect of the present invention is to provide methods for producing an Ethanol/Coal synthesization that approaches the BTU content of Gasohol.

In one embodiment of the present invention, the method for synthesizing hydrocarbons of coal with ethyl alcohol includes the Steps of extracting hydrocarbons from the coal using a release agent and synthesizing the extracted coal hydrocarbons with an ethyl alcohol product to produce a fuel suitable for use in an internal combustion engine. Some alternative embodiments further include the Steps of re-distilling the ethyl alcohol with a caustic soda and to reduce particle contamination and at least partially remove moisture from the Ethyl Alcohol in the extracting and synthesizing steps, adding the coal in the re-distillation Step at a ratio of about 1.5 pounds per gallon of ethyl alcohol.

Steps for implementing any combination of the above functions are also described.

Other features, advantages, and object of the present invention will become more apparent and be more readily understood from the following detailed description, which should be read in conjunction with the accompanying drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention is best understood by reference to the detailed figures and description set forth herein.

Embodiments of the invention are discussed below with reference to the Figures. However, those skilled in the art will readily appreciate that the detailed description given herein with respect to these figures is for explanatory purposes as the invention extends beyond these limited embodiments. Hence, it is to be understood, however, that the present invention may be embodied in various forms. Therefore, specific details disclosed herein are not to be interpreted as limiting, but rather as a basis for the claims and as a representative basis for teaching one skilled in the art to employ the present invention in virtually any appropriately detailed system or manner.

One aspect of the present invention is to provide methods for producing a novel fuel for the gasoline-powered internal combustion engine and an additive for the diesel combustion engine. Another aspect of the present invention is to provide methods for producing an Ethanol/Coal synthesization that approaches the BTU content of Gasohol.

In one embodiment of the present invention, ethyl alcohol, or what is known as denatured ethyl alcohol, is blended with methanol and synthesized with the hydrocarbons of coal. Using, for example, without limitation, a ‘release agent’ or heat, the coal hydrocarbons are extracted (i.e., “released”) and synthesized with ethyl alcohol to produce a fuel that could replace imported petroleum-based gasoline for the internal combustion engine. This would eliminate costly geographic petroleum searches, production, and oil platforms. Moreover, a processed fuel of ethyl alcohol and coal would be high in octane and have minimal exhaust impurities.

The United States alone possesses 27 percent of the world's known coal deposits, much of which is anthracite and high-grade bituminous. Many countries other than the United States may also domestically produce an ethyl alcohol coal-based fuel according to an embodiment of the present invention, thus lessening the need to import foreign crude oil.

In order to clarify the present invention, the following definitions are provided.

Ethyl alcohol is also known as ethanol. Ethyl alcohol can be distilled from any grain, fruit and fruit remains, such as the discarded pulp after the grape has been pressed to make wine. For examples, without limitation, sugar cane and sugar beets can easily be distilled to make ethyl alcohol.

Ethyl alcohol is also widely commercially available. Ethyl alcohol synthesized with coal hydrocarbons would also increase the volume of fuel.

Release Agents

Various exemplary and suitable release agents and related characterizing information

will next be described and listed by way of example, without limitation. Suitable release agents include, but are not limited to:

Given that coal is an inorganic hydrocarbon and Ethanol is an organic hydrocarbon; it

is preferred to have an inorganic Release Agent.

Acetone CH3COCH3 is a colorless, volatile, extremely flammable liquid. It is found and derived through the distillation of wood, sugar and cellulose. However, as acetone is derived from an organic source; distillation of wood, sugar and cellulose, it is an adequate but less preferred Release Agent in many practical applications.

Amyl is the monovalent radical C5H11 of any various isometric forms.

A ketone is one class of reactive organic compounds in which the divalent carbonyl group, CO, combines with two hydrocarbon radicals. The general formula is R1(CO)R2.

Methyl is the monovalent organic radical CH3. It may be produced by the thermal decomposition of wood.

Xylene is any of three colorless hydrocarbons, C8H10, which may be derived from coal tar, wood tar and petroleum.

By “release agent” is meant a compound or process that releases hydrocarbons inherent in coal. The release agent chemically (and physically) penetrates the coal because of a much attenuated molecular structure. It then separates the hydrocarbons which, when inundated with ethanol and heated to a desired temperature, for example, without limitation, 160 degrees (71.1degrees Celsius), blend with the expanding ethanol molecules. Various release agents are contemplated in the present invention. By way of example, and not limitation, methyl N-amyl ketone, xylene, acetone, xylene ethyl benzene, gasoline, and combinations thereof are suitable release agents. These release agents are widely commercially available. Methyl N-amyl ketone alone is a particularly advantageous release agent in some applications. In many applications, Methyl N-amyl Ketone and Xylene will be the preferred Release Agents.

Acetone has great penetrating qualities but has a high evaporation rate. Accordingly, in one embodiment, acetone may be mixed with another release agent, e.g., xylene that has a more moderate evaporation rate. Other combinations and release agents will be apparent to one skilled in the art. Ethanol used in the fuel making process is also, to a lesser extent, a release agent. As an alternative to the aforementioned chemical release agents, heat may be used as a release agent, as described in more detail below.

Various types of coal may be used in embodiments of the present invention. There are four basic types of coal. Anthracite coal is the hardest, possesses the highest carbon content, lowest sulfur and moisture content of the coals. Anthracite coal was formed in North America about 300 million years ago. After numerous climatic and seismic changes when the Earth's land mass were one super-continent called Pangaea, continents drifted apart, until checked by contra-faults which trapped and compressed ancient forest deposits. Coal beds east of the Appalachians were compressed to the extreme degree which resulted in a high carbon quality; impurities such as sulfur were expunged. Anthracite coal beds in North America are found at steep pitched angles along five counties of eastern Pennsylvania; Schylicill, Carbon, Luzerne, Northernaberiard, Lackawanna, Columbia, Dauphin and Sullivan Counties. Of the estimated 16 billion tons of anthracite coal located at the northeastern part of Pennsylvania, about half is recoverable. On the West Coast the State of Washington also has anthracite coal deposits. The State of Alaska has an estimated 3 billion tons of recoverable anthracite coal. The anthracite coal beds of the United Kingdom and Western Europe are for the most part depleted. It is known that there are vast tracts of coal beds in Antarctica, although the amount of anthracite in this location is unknown.

Bituminous (or soft coal) has a lower carbon content than anthracite. This type of coal is high in volatile gases, ash and moisture. With regard to the present invention, the dust particles from bituminous could be remedied by a simple filler. Such a filtration system may be used with other types of coal as well.

Sub-bituminous and lignite (brown) coal may be less advantageous than anthracite and bituminous coal for making a ethanol/coal hydrocarbon fuel, but may be appropriate in certain applications.

The hydrocarbons utilized in the present invention are located in the carbon content of coal. Sulfur is a semi-toxic nonflammable byproduct found in coal. Although sulfur is a lubricant agent when present in the fuel of the internal combustion engine, because sulfur is nonflammable it is emitted through the exhaust. Hence sulfur is a serious atmospheric pollutant.

Anthracite coal has a carbon content between 86 to 98 per cent. One pound of anthracite has an estimated 15,000 BTUs. Accordingly, an estimated 2.4 pounds of Anthracite Coal would be required to be synthesized with Ethanol, in an embodiment of the present invention, which results in a fuel similar in energy content with gasohol. Bituminous coal has a carbon content from 45 to 86 per cent and a BTU value per pound between 10,500 to 15,500. Accordingly, an estimated 3 to 2.4 pounds of Bituminous Coal would be required to be synthesized with Ethanol in an embodiment of the present invention.

Sub-bituminous Coal has a carbon content between 35 and 45 per cent with a BTU value between 8,300 and 13.000 per pound. Lignite Coal has a carbon content of 25 to 35 per cent and a BTU value of 4,000 to 8,300 per pound. Sub-bituminous coal has a relatively good BTU value, which would otherwise be useful; however, sub-bituminous, as well as Lignite, are known for their undesirably high sulfur content.

In one embodiment, anthracite coal is utilized. Anthracite coal has the highest carbon content and low sulfur and would likely produce the lowest emissions. Coal hydrocarbons would thus increase the British Thermal Unit and Energy content of ethanol which is approximately one third less than gasoline. Additionally, coal hydrocarbons Would also add a natural lubricant that, as is well-known in the art, ethanol lacks.

In another embodiment, bituminous coal is utilized. Bituminous coal contains sulfur. Accordingly, it may be desirable to purge any coal that contains this undesirable product.

Release agents can be used to isolate and release undesirable elements such as sulfur.

Acetone is often employed to purge coal of sulfur. Depleted coal, known as ‘coke,’ could be used as a low-grade fuel. In one embodiment, gasoline may be used as a purge/release agent to prepare coal to be synthesized with ethanol. ‘Coke,’ could be utilized as a fuel source when heat is required to distill and re-distill ethanol and the hydrocarbons of coal.

The evaporation rate of both ethanol and methanol is less than gasoline. This could be

remedied by blending ethanol or methanol with any release agents, e.g., acetone, methyl N-amyl ketone, or xylene, or combinations thereof.

It has also been known for more than a century that the diesel engine can be fueled by pure vegetable oil, soybean oil, and coconut oil, to name a few. However, the use of such oils causes several difficulties, including reluctance to start and undesirably high viscosity. An ethanol/coal hydrocarbon fuel of an embodiment of the present-invention combined with vegetable oil may be an acceptable substitute for the diesel engine. For example, without limitation, an ethanol/coal fuel of the present invention could be mixed with vegetable oil heated to some desired temperature, e.g., 150-160 degrees Fahrenheit. No modification of the diesel engine would be required.

Pure ethyl alcohol should not be used as a fuel for the internal combustion engine because it lacks a natural lubricant which is inherent in petroleum based gasoline. Pure ethyl alcohol contains minute amounts of water which can prematurely deteriorate an internal combustion engine. Additionally, an internal combustion engine fueled by pure ethyl alcohol could prove difficult to start when the ambient temperature is less than forty degrees Fahrenheit.

Initial distilled alcohol, because of the azeotropic syndrome, is usually between 160-190 proof, which in layman's terms is 80-95 per cent alcohol. This mixture is good enough to operate a modified gasoline internal combustion engine since the moisture appears to cool the exhaust valves. But if there are any mineral hydrocarbons within the alcohol a separation will take place that is not desirable. To remedy this, the alcohol may be placed in a container coated with caustic soda and/or quick lime. To have the measure amount of coal in the container at this time would be advantageous in many practical applications.

The following examples are provided as a means of illustrating some embodiments of the present invention and are in no way considered limiting of the present invention.

As noted above, methyl N-amyl ketone alone is an advantageous release agent. Another exemplary release agent is a combination of acetone and xylene. For example, without limitation, a mixture of 60 per cent acetone and 40 per cent xylene may be used. However, other proportions of various release agents may be utilized in the present invention.

In one embodiment, the coal is placed in a separate steel container where it is doused with the release agent for one half hour to forty five minutes. The container is then lowered into the ethyl alcohol and remains there from six to twelve hours.

The fuel is then heated to 160 degrees Fahrenheit. The heat may be provided by solar energy. When thus healed, the fuel with the synthesized coal hydrocarbons would expand exponentially.

The following table sets forth various exemplary parameters for practicing one or more embodiments of the present invention. The numbers given are for illustration purposes only, and one skilled in the art could readily determine other appropriate amounts and times for a particular application.

Duration Duration of coal/ of release synthesis Release agent with Coal Agent exposure Ethyl alcohol ethanol  3 pounds 1 pint 30 minutes  36 gallons  6 hours  30 pounds 2 quarts 30 minutes 360 gallons  8 hours 100 pounds 1 gallon 45 minutes 960 gallons 12 hours 200 pounds 2 gallons 45 minutes 2400 gallons  12 hours 1000 pounds  5 gallons 45 minutes 12000 gallons  12 hours

The temperature of the synthesis is preferably kept at or below 160 degrees Fahrenheit.

As an approximation, one and a half pound's of coal may be used with one gallon of ethanol in many applications.

It is contemplated that in some embodiments of the present invention that the combination of coal and the release agent could be incorporated into the distillation process of ethyl alcohol; however, the toxicity of the release agent is expected to disrupt the fermentation process.

When ethyl alcohol is First distilled it is at best 160-180 proof (80-90 per cent alcohol) which is good enough to operate a modified gasoline engine because the 20-10 per cent moisture in the fuel acts as a lubricant and a cooling agent. However, when 160-180 proof alcohol is mixed with gasoline (Gasohol), it separates because of the moisture. Hence, the ethyl alcohol has to be re-distilled with a caustic soda. The coal can be added to the redistillation process at a ratio of one point five (1.5) pounds per gallon of ethyl alcohol. By implementing the coal in the redistillation, there would be no need to have a direct coal immersion with the final product with the alcohol, thus minimizing particle contamination. The distillation process would automatically eliminate undesired coal particles. The remaining coal in the redistillation process would assist for the caustic soda and draw out moisture in the Ethyl Alcohol. It is contemplated that the redistillation of ethanol with coal would be the most efficient method to extract and synthesize the hydrocarbons of coal and ethanol.

It should be noted that to create an azeotropic syndrome caustic soda and/or quick lime has been successfully used to draw out the remaining moisture. It is contemplated by the present invention that the coal used therein could substitute the caustic soda and/or quick lime to draw out the remaining moisture and simultaneously add to the BTU content of the fuel

A chemical Release Agent could be eliminated by healing the coal then lowering it into the ethyl alcohol. However, some caution should be exercised because the boiling point of ethyl alcohol is a mere 78 degrees Celsius or 172.4 degrees Fahrenheit. The auto-ignition temperature is 363 degrees Celsius or 685.4 degrees Fahrenheit. Coal heated to 35 degrees Fahrenheit below the flash point of ethanol would release the hydrocarbons.

In some strait forward applications of the foregoing embodiment, if the Coal is made to simmer with the Release Agent and then be submerged with Ethanol for the number of hours recommend above, what is referred to as a, ‘passive phase,’ would result with a limited degree of hydrocarbon synthesization. One problem that tends to arise is the evaporation of the Ethanol and Coal dust particles, which generally requires a suitable filtration system. At this stage, for many practical applications, it is desirable to distill the Coal and Release Agent with Ethanol.

Under ideal conditions a sugar sluice at a temperature of 75-85 degrees when mixed with yeast will produce after 48 hours a liquid of 18 per cent alcohol which is far below what can fuel a gasoline Internal Combustion Engine. To improve this sluice to a usable level, it can be processed by means of an Instillation/Condenser plant. After the initial instillation an alcohol content of approximately 35-40 per cent (or 70-80 proof) can be attained, which is about the same alcohol content of commercial brandy. 35 to 40 per cent (70-80 proof) alcohol is still far too low to fuel an Internal Combustion Engine. The third distillation produces an alcohol content between 80 and 90 percent (160-180 proof), which adequate to fuel a gasoline Internal Combustion Engine. It is at this stage that the Ethanol is preferably synthesized with the Coal and the Release Agent and then distilled once again.

It is contemplated that for some implementations of the present invention, depending upon the particular embodiment details, the final fuel product could contain hydrocarbons that the gasoline internal combustion engine can not safely burn. Coal contains many hydrocarbons and it is within the realm of possibility that a diesel fuel could also be manufactured. In such a case, a heavier fuel would settle and in accordance with an alternative embodiment of the present invention the heavier fuel, such as but not limited to, any diesel product, would preferably be layered below the alcohol/coal hydrocarbon mixture. Any moisture that would find its way into this embodiment would tend to settle to the bottom layer where it could be discarded.

Having fully described at least one embodiment of the present invention, other equivalent or alternative methods of synthesizing hydrocarbons of coal with ethanol will be apparent to those skilled in the art. For example, one skilled in the art could readily modify the release agent selected, the ethyl alcohol/coal ration, temperature, duration, and/or release agent/coal ratio within the scope of the present invention. The invention has been described above by way of illustration, and the specific embodiments disclosed arc not intended to limit the invention to the particular forms disclosed. The invention is thus to cover all modifications, equivalents, and alternatives falling with the spirit and scope of the following claims. 

1. A method for synthesizing hydrocarbons of coal with ethyl alcohol, the method comprising the Steps of: blending an ethyl alcohol with methanol to make a first intermediate product; blending the first intermediate product with a first release agent to increase the evaporation rate thereof, and produce a second intermediate product; extracting hydrocarbons from the coal using a second release agent; synthesizing the second intermediate product with the extracted coal hydrocarbons to produce a fuel suitable for use in an internal combustion engine.
 2. The method of claim 1, in which said ethyl alcohol is a denatured ethyl alcohol.
 3. The method of claim 1, in which said second release agent is heat.
 4. The method of claim 1, in which said first and/or second release agent is/are inorganic.
 5. The method of claim 1, in which said second release agent comprises any combination of acetone, amyl, ketone, methyl, methyl N-amyl ketone, xylene, xylene ethyl benzene, Ethanol, or gasoline.
 6. The method of claim 1, in which said second release agent is acetone and is mixed with a third release agent.
 7. The method of claim 6, in which said third release agent is xylene, and combined into the mixture so as to result in a reduced evaporation rate of the mixture.
 8. The method of claim 67, in which the mixture ratio is 60 percent acetone and 40 percent xylene.
 9. The method of claim 61, in which the coal is anthracite coal.
 10. The method of claim 61, in which the coal is anthracite, bituminous, sub-bituminous or lignite coal.
 11. The method of claim 61, further comprising the Step of using said first and/or second release agents to release sulfur.
 12. The method of claim 61, further comprising the Step of combining said fuel with a vegetable oil to thereby produce a suitable fuel for a diesel engine.
 13. The method of claim 61, in which if there are any mineral hydrocarbons within the alcohol, further comprising the Step of placing the alcohol in a container coated with caustic soda and/or quick lime and further placing a suitable amount of the coal into said coated container to carry out said synthesizing method.
 14. The method of claim 61, in which said Steps of extracting hydrocarbons and synthesizing further comprise the Steps of: placing the coal in a container; at least partially covering the coal with said second release agent for a suitable amount of time to extract at least some of the coal's hydrocarbons; combining at least part of said extracted hydrocarbons with said second intermediate product for a suitable amount of time to achieve at least partial combination thereof; and heating said hydrocarbon combination for a suitable amount of time to at least partially synthesize the coal hydrocarbons.
 15. The method of claim 14, in which the Step of heating is performed at or below about 160 degrees Fahrenheit.
 16. The method of claim 14, in which the Step of partially covering the coal with said first release agent is done for about one half hour to forty five minutes.
 17. The method of claim 14, in which the Step of combining said extracted hydrocarbons with said second intermediate product is done for a about six to twelve hours.
 18. A method for synthesizing hydrocarbons of coal with ethyl alcohol, the method comprising the Steps of: extracting hydrocarbons from the coal using a release agent; and synthesizing the extracted coal hydrocarbons with an ethyl alcohol product to produce a fuel suitable for use in an internal combustion engine.
 19. The method of claim 18, further comprising the Steps of: re-distilling the ethyl alcohol with a caustic soda; to reduce particle contamination and at least partially remove moisture from the Ethyl Alcohol in said extracting and synthesizing steps, adding the coal in the re-distillation Step at a ratio of about 1.5 pounds per gallon of ethyl alcohol.
 20. A method for synthesizing hydrocarbons of coal with ethyl alcohol, the method comprising: Steps for extracting hydrocarbons from the coal using a release agent; and Steps for producing a fuel suitable for use in an internal combustion engine using said extracted hydrocarbons. 